Specialty Polymers for Automotive

Global automotive OEMs face the challenge of meeting upcoming CO2 and tailpipe emissions standards. In order to address these challenges, OEMs are focused on improving powertrain efficiency through engine downsizing and transmission down-speeding, increasing the electrification of their vehicles, lightweighting, and reducing fuel consumption.

Specialty Polymers is focused on these CO2 and emissions reduction technologies by offering high-performance polymers that offer heat and chemical resistance as well as dimensional stability.

Automotive Electrical and Electronics Systems

Sulfone Polymers Make a Visible Difference

Sulfone polymers are amorphous high-heat polymers that retain their mechanical strength in some of the toughest environments. Unfilled grades offer good ductility and are available in a range of transparent colors.

Semi-Crystallines Provide Reliable High-Temperature Performance

Amodel® polyphthalamide (PPA) is a family of high-temperature polyamides that retain their high strength and stiffness up to 280°C and maintain mechanical integrity after thousands of hours at elevated temperatures. Their low moisture absorption prevents blistering during IR soldering. These materials are highly resistant to many commonly used electronic cleaning agents, fuels, automotive fluids and road salts. Fast cycle times can lower molding costs.

Amodel® PPA

Amodel resins are available in an wide variety of grades—including high strength, toughened, conductive, high flow, laser welding and flame retardant grades—giving you more ways to optimize performance, processing and price.

Amodel® PPA Key Features

High strength and stiffness

Continuous-use temperature from 120-185°C at 5,000 hours

Withstands SMT processing up to 280°C

Low moisture absorption prevents blistering

Excellent dimensional stability

High flow for thin-wall designs and precision overmolding

Excellent electrical insulating properties

Good adhesion to silicone and epoxy

Meets established OEM specifications

Resists automotive fluids, fuels and road salts

Xydar® LCP

Xydar® liquid crystal polymer (LCP) is a highly crystalline glass-filled resin that offers exceptional flow properties. It can withstand SMT assembly, including lead-free solder reflow, and retains its high strength and stiffness up to 300°C.

Fuel Systems

Improve Fuel Economy & Reduce Emissions

The global need to reduce evaporative emissions along with changes in fuel formulations have sparked a strong interest in higher-performing plastics, fluids and elastomers for use in automotive and other fuel-burning engines.

High-Temperature Components

Amodel® PPA Replaces Metal

For over 15 years, Amodel® PPA has successfully replaced metal in fuel system components where heat is a major consideration. With a heat deflection temperature of 280°C and continuous-use temperatures from 120-180°C, Amodel® PPA delivers the thermal performance you need for the short term as well as the long haul.

Key Features

High strength and stiffness

Ultra-low permeation

Bio-diesel and flex fuel compatibility

Long-term fuel contact from 60-125°C

Continuous use from 120-180°Cv

Resistance to automotive fluids, cleaners and road salts

ESD and toughened grades available

Multi-Layer Extrusion

Ixef® PARA Reduces Complexity and Cost with Fewer Layers

Ixef® BXT-2000/0203 has been approved by the California Air Resources Board (CARB) and the U.S. Environmental Protection Agency (EPA) as a barrier solution for three-layer fuel tank systems for small-engine fuel tanks such as lawnmowers, snow blowers, weed trimmers and generators.

Chemical Resistance in Flex Fluids

Fluid Testing in Ethanol Blends, 70 hrs @ 60°C

Fluid Testing at Methanol Blends, 168 hrs @ 23°C / 40°C

Fluid Testing in Biodiesel, 336 hrs @ 150°C

Optimal Pipes, Tubes and Hoses

Algoflon® DF

Algoflon® DF powders are used for pipes and tubings for fuel transport in automotive systems with exceptional performance:

Chemical inertness in aggressive environments

Thermal resistance

Electrical properties

Non-stick characteristics in a wide range of temperatures from cryogenic to 260°C

Solef® PVDF

Solef® PVDF qualities of impermeability and chemical resistance recommend their use in automotive fuel transport systems. A layer of Solef® PVDF within the construction of a multi-layer fuel line enhances the strength, permeation resistance and durability of the hose.

Lubrication

Fomblin® PFPE

Fomblin® PFPE is a family of high performance fluorinated lubricants with exceptional properties such as:

Compatibility with fuels

Wide temperature service range

Oustanding properties at low temperature

Low evaporation weight loss, which extends the durability of the lubricant and of the lubricated components

Non-flammable and safe

Oxidation and thermal stability and resistant to most automotive solvents, oils, fluids and gases.

Air Induction Systems

Amodel® PPA Outperforms Conventional Nylons

With a heat deflection temperature of 280°C (536°F) and continuous-use temperature up to 210°C (410°F), Amodel® polyphthalamide (PPA) can take the heat in under-the-hood applications that are too demanding for conventional nylons and polyesters. This allows charge air cooler (CAC) housings, airflow valves, throttle bodies and other components molded from Amodel PPA to maintain their high strength and stiffness along with excellent creep and fatigue resistance when exposed to high heat and thermal cycling.

Key Features

Excellent mechanical properties over a broad range of operating temperatures and pressures

Continuous use up to 210°C (410°F)

Excellent resistance to automotive fluids, cleaners and road salts

Low moisture absorption

Excellent dimensional stability

Typical Applications

CAC Hot Air Ducts

CAC Housings

Diesel Airflow Valves

EGR Valves & Housings

Throttle Bodies

Turbocharger Housings

Wear-Resistant Plastics for Turbocharger Components

Turbocharger bushings, seal rings and other internal components are some of the most demanding applications in air induction systems. They must withstand extreme temperatures, wear, loads and aggressive chemicals in lubricated and non-lubricated environments over a wide range of critical pressures and velocities.

Wear-resistant grades of Torlon® PAI and KetaSpire® PEEK are formulated to give you just the right combination of mechanical and tribological properties to effectively replace metal in high-temperature friction and wear applications.

For comparable PEEK performance with up to 30% lower cost, consider our new wear-resistant AV-700 grades of AvaSpire® PAEK.

Key Features

Long-term use from 120-265°C (248-509°F)

Short-term use up to 280°C (536°F)

Lubricated and non-lubricated environments

Self-lubricating for longer life

Lighter weight and less noise than metals

Non-corrosive and non-galling

Typical Applications

Bearing Retainers

Bushings

Compressor Wheels

Isolation Disks

Seal Rings

Fomblin® PFPE High Performance Lubricants

Fomblin® PFPE fluorinated fluids are high performance lubricants with exceptional properties such as:

Fuel compatibility

Low evaporation weight loss

Low noise

High viscosity index

Anti-wear properties

No carbonized residue formation

Very long service life at high and low temperatures (-40°C to 150°C)

Satisfying Extended Warranties - Components must be designed for lifetime lubrication

Exceptional low temperature starting torque

Compatibility with plastics, metals and elastomers commonly used in automotive design

Elimination of NVH (Noise, Vibration, Harshness)

Not affected by most automotive solvents, oils, fluids and gases

Oxidation and thermal stability

Applications

Air Induction Systems

Fan & Radiator Lubrication for Cooling & Heating Systems

Contact Lubrication for E/E systems

Fuel system mechanical and hydraulic components

Mechanical components

Jacket and Primary Insulation

Sophisticated control and sensing systems have stringent demands for their cabling which only fluoropolymers can deliver. Solvay offers Hyflon® PFA/MFA®, Halar® ECTFE and cross-linkable grades of Solef® PVDF.

For applications such as automotive push-pull cables, Hyflon® MFA® offers:

Amodel® PPA Outperforms Conventional Nylons

Polyphthalamides (PPA) outperform standard polyamides with higher strength and stiffness at elevated temperatures, better retention of properties in humid environments, and greater resistance to a broader range of chemicals.

With a heat deflection temperature of 280°C (536°F) and continuous-use temperature up to 210°C (410°F), Amodel® PPA (polyphthalamide) can take the heat in under-the-hood applications that are too demanding for conventional nylons and polyesters.

Air Induction Components

Amodel® PPA Outperforms Conventional Nylons

With a heat deflection temperature of 280°C (536°F) and continuous-use temperature up to 210°C (410°F), Amodel® PPA can take the heat in under-the-hood applications that are too demanding for conventional nylons and polyesters. This allows charge air cooler (CAC) housings, airflow valves, throttle bodies and other components molded from Amodel PPA to maintain their high strength and stiffness along with excellent creep and fatigue resistance when exposed to high heat and thermal cycling.

Key Features

Excellent mechanical properties over a broad range of operating temperatures and pressures

Continuous use up to 210°C (410°F)

Excellent resistance to automotive fluids, cleaners and road salts

Low moisture absorption

Excellent dimensional stability

Typical Applications

CAC Hot Air Ducts

CAC Housings

Diesel Airflow Valves

EGR Valves & Housings

Throttle Bodies

Turbocharger Housings

Air Induction System Turbocharger Components

Amodel® PPA Outperforms Conventional Nylons for Turbocharger Housings

With a heat deflection temperature of 280°C (536°F) and continuous-use temperature up to 210°C (410°F), Amodel® PPA can take the heat in under-the-hood applications that are too demanding for conventional nylons and polyesters. This allows charge air cooler (CAC) housings, airflow valves, throttle bodies and other components molded from Amodel PPA to maintain their high strength and stiffness along with excellent creep and fatigue resistance when exposed to high heat and thermal cycling.

Key Features

Excellent mechanical properties over a broad range of operating temperatures and pressures

Continuous use up to 210°C (410°F)

Excellent resistance to automotive fluids, cleaners and road salts

Low moisture absorption

Excellent dimensional stability

Cooling & Heating Systems

Full-Size Performance for Down-Sized Engines

Amodel® PPA has successfully replaced die-cast aluminum in engine coolant systems for over 15 years. This high-performance polyamide offers fundamental performance advantages over conventional polyamides due to its aromatic nature and is routinely used to replace metal in under-the-hood applications where heat, humidity and chemical resistance are major considerations.

Similar to Ryton® PPS, Amodel® PPA offers excellent dimensional stability in corrosive, high-temperature environments. In addition, it delivers better fatigue and impact resistance, better strength retention at 130°C (266°F) after prolonged exposure to engine coolants as well as faster cycle times when molding.

Fatigue Resistance Properties

Fatigue resistance at 32 Hz and 170°C (338°F)

Elongation Properties

Elongation at 130°C (266°F)

Long-Life Coolant Exposure

Tensile strength after exposure to Long Life Coolant

Weldline strength after exposure to Long Life Coolant

Tensile Fatigue Properties

Tensile fatigue at 10Hz and 150°C (302°F)

Electrical / Electronics Systems

Reliable High-Temperature Performance

Amodel® PPA is a family of high-temperature polyamides that retain their high strength and stiffness up to 280°C and maintain mechanical integrity after thousands of hours at elevated temperatures. Their low moisture absorption prevents blistering during IR soldering. These materials are highly resistant to many commonly used electronic cleaning agents, fuels, automotive fluids and road salts. Fast cycle times can lower molding costs.

Amodel® PPA resins are available in an wide variety of grades—including high strength, toughened, conductive, high flow, laser welding and flame retardant grades—giving you more ways to optimize performance, processing and price.

Key Features

High strength and stiffness

Continuous-use temperature from 120-185°C at 5,000 hours

Withstands SMT processing up to 280°C

Low moisture absorption prevents blistering

Excellent dimensional stability

High flow for thin-wall designs and precision overmolding

Excellent electrical insulating properties

Good adhesion to silicone and epoxy

Meets established OEM specifications

Resists automotive fluids, fuels and road salts

Fuel Systems

Amodel® PPA Replaces Metal

For over 15 years, Amodel polyphthalamide (PPA) has successfully replaced metal in fuel system components where heat is a major consideration. With a heat deflection temperature of 280°C and continuous-use temperatures from 120-180°C, Amodel PPA delivers the thermal performance you need for the short term as well as the long haul.

Key Features

High strength and stiffness

Ultra-low permeation

Bio-diesel and flex fuel compatibility

Long-term fuel contact from 60-125°C

Continuous use from 120-180°C

Resistance to automotive fluids, cleaners and road salts

ESD and toughened grades available

Typical Applications

Fuel flanges

Rollover valves

Quick connects

Filter housings

Fuel rails

Sender units

Fuel and vapor lines

Throttle bodies

Carburetors

Fuel Compatibility

The compatibility of Amodel® PPA with many current and potential future fuel blends was evaluated in extensive laboratory testing. This included exposure to bio-diesel, diesel, and diesel with aggressive water for 6,000 hours at 125°C (to simulate under-the-hood conditions) and exposure to fuel C, flex fuels, and auto-oxidized fuels for 5,000 hours at 60°C (to simulate fuel tank conditions).